Method of prefabricating parts for concrete structures



July 25, 1950 v c. DOBELL 2,516,453

ms'mon OF PREFABRICATING PARTS FOR CONCRETE STRUCTURES Filed Feb. 14, 1946 s Sheets-Sheet 1 INVENTOR ATTORNEYS July 25, 1950 Filed Feb. 14. 1946 C. DOBELL METHOD OF PREF'ABRICATING PARTS FOR CONCRETE STRUCTURES '5 Sheets-Sheet 2 INVENTOR w "MM ATTORNEYS July 25, 1950 c. DOBELL 2,516,453

METHOD OF PREFABRICATING PARTS FOR CONCRETE STRUCTURES 5 Sheets-Sheet 3 Filed Feb. 14, 1946 Il llll ATTORN EYS Filed Feb. 14, 1946 5 Sheets-Sheet 4 July 25, 1950 c. DOBELL 2,516,453 METHOD OF PREFABRICATING PARTS FOR CONCRETE STRUCTURES lzliigiiillli'l a ATTORNEYS July 25, 1950 c. DOBELL METHOD OF PREFABRICATING PARTS FOR CONCRETE STRUCTURES 5 Sheets-Sheet 5 Filed Feb. 14, 1946 INVENTOR Czlrzazafiafiell ATTORNEYS Patented July 25, 1950 "IT EED, STATES METHOD OFPBEFABRICATING PAKTS FOR CONCRETE STRUETURES vCurzon- Dobeli, New; York, assignor tqglreloadEnterprises,Inc., a corporation of Delai. W are ---Application February 14, 1946, Serial No. 647,486

3 Claims.

This invention relates to theiprefabrication of -vwconcrete structural members; and more particulafiyto therprefabrication of reinforced concrete -structura1:units' adapted to beassembled to form :1 "dwellings;barns,inuthouses; or other buildings.

. 'JZhet-recenttrenditowardbetter housing conditionssthronghout thepworld has created-a demand for arrextremelyiowecostitype of housing that is 1'. highlyflwea-thertresistant and.,:du-rab1e. To :meet

"this loweicost'housinga by manufacturing it from 1 concretei: Immzder :to; manufacture s h 10 m- -=-c1-.e.te structures :im-sitn, fit is; necessary to=.set; up forms atizeachlccationygpour org-otherwise zv -place 1"17116 :concretez: and=:thenremove :the forms; r. :a slowqorocesses compared;withpr,eparing re- 'z-tformedrconcrete. tpartsxaand ,-ass.em-blinghem at --z.-the:,:1ocation:f 1.: Chnsequently', it has gbeen found 'zazdesirable :tm utilizespreiormedgconcrete --p arts.

5:;Imorder-tmmakeaprczformedconcrete-p r 5 it ,ziha-s::sheretofore;:beenvxnecessary to; first prepare .QI'IIlOldSQ'lIIOlid thetconcrete-"parts, remove the molds, moverthezoncrete parts t0?SOIYIGTDIELCEpWhQEBiiZhBY canrcunei-or bexcured; and thenshipthe, parts to :-.-,;necessary andzthe: factory; spacerequiredare-thus major items in. the -cos.t1of--,manufac.ture.

.23: According. toerthe-spresent:invention, much of thisndifiicultyrand costqmay beavoided by formssthatttheyparts to -be ;mo1ded-can be moldedand ezc-uredzwithout moving them .andw-the parts can then be picked upand loadeddirectly onto a. cone iveyance' which :t'hey-xare. to the shipped-.iwsuch v a; in which to carry ouhthe manufacturin process, eliminatesrzar'agreat-ideal of handling of -tthe. molds andirthe formed. but'tuncured parts; and-;even .makes-iexpedientethezpicking upand-shipping of :ritherfinalizproducts. a; .-:.T;' It .iszpreferredeaccnrdingitoithe new pnocess, to utilizerrazr-section of::1.eve1-.,. o ubstantiallm level earthaand to; last out; on:,-this -s8 Q- ?i0n, ofr earth a series Jar-rows nbmoldssgztdeeply enough in the i i earth so: :thatatheyt-cantbe flooded: with z-watenfor eretiring:thmmoldedapmducts, and with the var-ious fiYIYOWS separated by roadways 7onto wrhichjtrucks cn-;othen-means-oficonveyance-may be. driven to mpick up -.thetfina1 -products.

s- Theez-moldsmthemselvesa may be prepared by excavating the earth to the approximat ishap i aoithearticles to ;be,--mo1ded; -and -lthenglining the earth; witheconcrete to: that-exact? outerdimen- -ssionsnfthezarticlesus, lining; can he placed in gee-me: 'eartineithernbyzinmlding 201 :bimpmnmatiqallyg the: place :of; :assemb1y;;-:The; amount/of; handling ting thecoriginalrmolds in-the open in-suchi aiway :prccessaeliminates EthBCIIGCBSSH'IYr fora-building;

e ebui l .e nst us e H9111; a tsptn el projecting concrete ento Peace-rate cam-. v b th t Once the,;mo1d;-has 0 en ormed tcanha eqred thisdemand an attempt hasbeen'made to provide; 10 formatiom-vthe -molds vvill b -;egated with time material to prevent concrete from dh the rwu a es and; he. products melq etw tthe hemmed in he a-b uri -q brib neumati nrci ,e;

; l5,--'erete-,-into z-, the';m(; 1ds.

; na c u s t it .e -.-tmane ac rc= fln i i-produ t: ytr qui ede e n qt i.

b p a edwt e t W nw v erthem 1 s a lre 10 er e a r ht eat-twillbe.fl ed. htwe ele qn.cur zA e o f .the cur-ing period the water;wi11 be a d he ir xol ed p. odu twilk t en .-.they areto be -used. 25; ,Ion the purpose of, illustratingatheinvention,

.. (they-a nde d win s h w he-imam t of two types, of; buildings, by them P 3 29885. H; Qne is an outhouse, ofwhich arverye rge number a e to; ecQn H G ensen ta eaurpo a in the tropics;v and the second is curved nootkiwellq i, ing, v, especially, suitable for, the tropics, of; which a large number are, a1s0 expected tov be ;con- .structed; To, manufacture the; preformed-mans tenthwabuilfinm an her teuzw t t are r qu r aquite at' u be io twnes ofda il be requir d-.2 ltthewiwprkswete$ 9 .fec xyts yle, inside niubnildin stitweulda requi e i e tla ee ctqr s.

I rt eidrawi w ws cit-see m etce hamesen .nventi n;

m m nta-wi h th rin iple eft i n 11;

,l ie -ret-fii ea ir an v ewetttw erons of molds prepared according to this inventiomfg diflerin place.

dowel pins 21 may be embedded in the main base Figure 7 is a cross-sectional view of the mold arrangement shown in Figure 6 and taken on lines ll of Figure 6;

Figure 8 is a view of an assembled building constructed from the parts molded in the mold arrangement shown in Figures 6 and 7;

Figure 9 is a cross-sectional view of the building shown in Figure 8;

Figure 10 is a detailed view in cross-section of the footing construction of the building of Figure 8;

Figure 11 is a plan view of the building of Figure 8;

Figure 12 is a detailedsectional view taken on lines i2i2 of Figure 11;

Figure 13 is a detailed sectional view taken on lines l3l3 of Figure 11;

Figure 14 is a detailed sectional view taken on lines i4l4 of Figure 11; and

Figure 15 is a detailed sectional view taken on lines l--l5 of Figure 11.

As illustrated in Figures 1 to 5, inclusive, the principles of this invention have been applied to the manufacture of the parts for a small, sturdy, economical, easily cleanable outdoor toilet.

As illustrated in Figures 3, 4 and 5, such a structure consists of a main base member 20, arcuate'wall members 2|, 22 and 23, a roof member 24, a commode member 25 and a smaller base member 26.

The members are so constructed that the main base member 28 and the smaller base member 26 may be placed in the ground, the wall members 2|, 22 and 23 may rest thereon and the roof member 24 may be supported by the wall members. During their formation, each of the parts is provided with means by which it may be interlocked to adjacent parts so that the structure when completed will be securely locked Thus, as shown in Figure 5, angular plate ZOand the side members 2!, 22 and 23 may be provided with openings in their lower edges to receive these dowel pins and hold them in place relative to the base plate. In-order to prevent the dowel pins 21 from breaking the lower edge of the side members 2|, 22 and 23, it has been found desirable to form the openings in the lower edges of the side members by embedding therein pipes 28 having an internal diameter of the proper size to receive the dowel pins 21.

In a similar manner, the roof member 2A may have formed therein a-ngular dowel pins 29 which are adapted to be received in openings of the upperedges of theside members, which openings and he'nce'extends outwardly from the main base member 20 and has its outer end mounted on the small base member 25 in the same manner that the other side members are mounted on the main base member. The inner edge of this third side "member, instead of being attached to the main base member and the roof, is attached to the adjacent side member "by means of an S-shaped dowel member 3! at its lower end and a U-shaped dowel member 32 at its upper end. These dowel members enter openings in the adjacent side member and in the reinforcing pipes 28 and 30 and also enter openings defined by pipe members 33 and 34 embedded in the edge of the third "side member 23.

Reinforcing material 35 is molded into any or all of the members as necessary, and the commode member may be mounted on base member 20 either in the same manner that the side members are mounted on the base member or in any convenient manner.

The formation of the preformed parts for the structure shown in Figures 3, 4, and 5 may be accomplished by use of an arrangement such as illustrated in Figures 1 and 2. In Figure l, a roadway 4B is flanked by two rows 4! and 42 of molds prepared in accordance with this invention. The roadway will have a width and a surface satisfactory for use by whatever vehicles are to be used for removing the completed preformed elements. Along one side of the road is formed a series of molds 4| for the arcuate side members of the desired structure. These molds, as previously stated, are formed by excavating the earth and lining the excavated portions to the desired dimensions with concrete, either poured or pneumatically projected.

Wood or metal inserts may be used where necessary to produce sharp corners or other unusual configurations and any desired reinforcing can be positioned in the mold prior to or during molding. The mold surfaces themselves will be coated with castor oil or some other material that will prevent the adhesion of concrete to them prior to use, and this treatment will be repeated as often as necessary during use.

When the series of molds in a row have a generally arcuate form, as in the case of the series of molds for the arcuate side members of the particular structure illustrated in Figures 3, 4 and 5, the molding may conveniently be accomplished by the use of a ditch-lining machine such as the machine shown in Patent No. 2,297,099, granted to John M. Crom on September 29, 1942. If preferred, however, the products to be molded may be formed by applying cement by a hand-operated pneumatic projection device or by pouring the cement in place and troweling it into final shape.

As illustrated by the row of molds on the other side of the road in Figure 1, the roof member 24, the main base member 20, the commode member 25 and the small base member 26 may be cast in another row of molds opposite the molds which cast the side members. The molds for these members are prepared in exactly the same manner but since they are not of uniform arcuate shape it is generally more expedient to prepare these members by hand or by a hand-operated pneumatic projection device.

Having formed the products to be molded in the mold, they may be allowed to remain there while the molds are flooded and curing takes place. After curing, the completed parts may be moved directly onto a truck or other vehicle on the roadway 40. The molds drained of water either before or after the prefabricated parts are removed, are thus immediately available for the preparation of additional preformed parts.

'As illustrated in Figures 6 to 15, inclusive, the principles of this invention are not limited to the preforming of parts for any particular type of structure but may be applied to the formation of parts for a wide variety of structures. Thus,

reinforced concrete sections, instead of from metal.

As illustrated, each building is formed from a series of arcuate members 50, that function as both top and sides, a series of partition members 5| and a ridge pole or cover member 52, that covers the line where the arcuate members are joined. The arcuate members 50 are constructed so as to lock together along their laterally adjoining edges as shown in Figure 13 and to lap over and hold the end partitions in place as shown in Figure 12. They may also be constructed so as to fit over and look into place the various interior partitions as shown in Figure 14. Since the arcuate members only extend to the center of the top of the building and it takes two members to make a complete building section, each member is provided with a plurality of bolt holes at its top edge, through which it may be bolted to the opposite member. A ridge or a cover plate 52 is so shaped as to fit over the place where the two arcuate members are bolted together, in such a manner as to prevent the entrance of water. This member also may be bolted in place. In order to provide ventilation, it has been found desirable to provide clearance, as shown at 53 in Figure 15, between the edges of the ridge plate and the arcuate members and then to provide openings -54 in the arcuate members under the ridge plate,

In preforming the parts for this construction, a road 60 may be provided with rows of molds BI and 62 arranged along its opposite sides, in the same manner as was done in preparing the preformed parts for the smaller structure. The molds 6! on one side of the road may comprise the molds for the arcuate members, and the molds on the other side of the road 62 may comprise the molds for the partitions and cover plates. These molds may be formed, treated and used in exactly the same manner as has already been described in connection with Figures 1 and 2.

In some instances it may be desirable to force water under pressure into the molds under the molded products to loosen these products hydraulically from the mold after formation. For this purpose a water pipe or pipes may be connected to an opening or openings in the bottom of the mold.

Numerous modifications in the method of prefabrication described may be made without departing from the spirit of this invention and many types of structures produced by the application of its principles. It is intended therefore that this invention not be limited by the specific details of the disclosure but only as indicated by the appended claims.

What is claimed is:

1. A method of prefabricating parts for concrete structures that comprises forming molds for said parts in a series of elongated rows in the earth, separated by roadways, by excavating portions of the earth to form excavations having approximately the same shape as the parts to be molded, lining the excavated portions with concrete and covering the surface of the concrete lining with a material that will prevent the ad hesion of concrete thereto, thereafter pneumatically projecting concrete onto the surface of the molds to form the parts to be prefabricated, flooding the molds to cure the parts so formed in situ, and removing the parts so formed from the molds.

2. A method of prefabricating parts for concrete structures that comprises forming molds for said parts in a series of elongated rows in the earth, separated by roadways, by excavating portions of the earth to form excavations having approximately the same shape as the parts to be molded, lining the excavated portions with concrete and covering the surface of the concrete lining with a material that will prevent the ad hesion of concrete thereto, thereafter placing reinforcing material in place in the molds and placing concrete around the reinforcing to form the parts to be prefabricated in the molds, flooding the molds to cure the parts so formed in situ, and moving the parts so formed directly onto a conveyance operating on the roadways between the rows of molds.

3, A method of prefabricating parts for concrete structures that comprises forming molds for said parts in a series of elongated rows in the earth, separated by roadways, by excavating portions of the earth to form excavations having approximately the same shape as the parts to be molded, lining the excavated portions with concrete and covering the surface of the concrete lining with a material that will prevent the adhesion of concrete thereto, thereafter placing re inforcing materials in place in the molds and pneumatically projecting concrete into the molds around the reinforcing materials to form the parts to be prefabricated in the molds, flooding the molds to cure the parts so formed in situ, and moving the parts so formed directly onto a conveyance operating on the roadways between the rows of molds.

CURZON DOBELL.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 1,111,131 Broughton Sept. 22, 1914 1,398,209 Van Bavegem Nov. 22, 1921 1,416,844 Larsen May 23, 1922 1,460,676 Larsen July 3, 1923 1,869,265 Leriche et al July 26, 1932 2,112,452 Copeman Mar. 29, 1938 2,364,522 Ganteaume Dec. 5, 1944 FOREIGN PATENTS Number Country Date 127,389 Great Britain May 27, 1919 773,709 Great Britain Nov. 1, 1904 

